Art of building material



March 1935- N. P. HARSHBERGER v ART OF BUILDING MATERIAL Filed Dec. 9,1932 I l J IN V EN TOR.

A TTORNEYS.

ting will Patented Mar. 19, 1935 PATENT OFFICE ART OF BUILDING MATERIALNorman P. Harshberger, Scarsdale, N. Y., as-

signor to Bakelite Building Products Co. Inc.,

New York, N. Y., a corporation of Delaware Application December 9, 1932,Serial No. 646,402

20 Claims.

This invention relates to improvements in the art of building materialand more particularly to building material for "use on walls, ceilings,floors or on any other surface where tiling or plastic block surfacingmaterial might be used.

The invention has reference to the economical formation of a section ofsurfacing material comprising a multiplicity of tiles or,plastic blockswherein the section may be applied to the surface as an individual unit.The invention may, however, be utilized in such form that each tile orblock formation is applied separately.

With the usual method of laying tiling or blocks wherein cement or thelike is utilized as a securing means, a number of disadvantageousphysical conditions and uneconomical practices are present. It isnecessary to obtain a bond between the substance forming the block andthe substance used as the binder between blocks, and if the binder usedis a dry mortar, quick settake place and a non-waterproof joint willresult. If the binder is of a cream-like consistency, it frequentlyoozes out between blocks and stains the face of the latter and thesurface surrounding it. In addition to the above-mentioned objectionablefeature of present day ,practices, shrinking frequently takes placewhenthe mortar between blocks sets and an imperfect bonding results. Ifa gum or asphalt of a hard variety is employed as the binder, checkingin the binder results. A gum or asphalt of the soft variety permitsdisplacement of one unit with respect to another. As a result of theoozing before mentioned it is necessary under present practices toperform a finishing operation on the wall or other surface after it hasbeen covered with the blocks and this finishing operation. consists ofan acid or abrasive treatment to produce a clean, unstained finish.

/ It is one of the objects of the present invention to overcome theabove-mentioned objectionable features of present methods of layingtiling or blocks by providing building material in which displacement ofone block with respectto another is eliminated, in which the oozing ofmortar or other binding material is prevented, and in which the layingof a wall, ceiling or the like is greatly faclitated'.

A further object. of the invention is to provide an improved methodoflaying tile blocks or the like wherein the latter may be pre-formed ingroups and wherein binding material is caused to enter the spacesbetween the individual tiles of each group and between the tiles ofadjacent groups in a very/novel manner to prevent staining of thesurface of the blocks.

A further object of the invention is to provide I an improved method oflaying tiles or blocks as above described wherein the binding materialmay be so formed as to cause it to be either flush with the surface ofthe blocks, in the form of grooves, or in the form of ridges.

With the above and other objects in view, the invention consists ofimprovements in the art of building material and all its parts andcombinations as set forth in the claims and all equiv-' alents thereof.

In the accompanying drawing in which the same reference numeralsindicate the same parts in all of the views:

Fig. 1 is an elevational view showing the webbing used as a base with amultiplicity of blocks formed thereon, the mesh of the webbing beingomitted in parts for purposes of clarity;

Fig.2 is a broken elevational view of the complete article showing thecovering sheet thereon;

Fi 3 is a. perspective view of a fragment of a wall showing the novelconstruction, parts being broken away;

Fig. 4 is a, cross-sectional view showing a fled form of covering sheet;

Fig. 5 is a similar sectional view showin another form of coveringsheet;

Fig. 6 is an elevational view of another form of unit;

V Fig. '7 is an elevational view showing a modified form of unit whereinonly a single block or tile is utilized, part being broken away; and

Fig. 8 is a cross-sectional view of another modified form of theinvention wherein the mesh is intermediate the blocks to permitreversal.

The article may be made in various other forms and shapes, thoseillustrated being merely shown byway of example.

Referring more particularly to Figs. 1 and 2. the unit utilizes abacking or webbing 1 made of either a flexible or rigid mesh of anysuitable material such as metal or cloth, or the webbin may be formed ofnetting, perforated sheet ma- \terial or exceptionally porous material.Secured to the face of the webbing and embedded at least flush with itsback is a plurality of blocks 2' formed of a plastic material which havebeen cast or molded into position and formed to represent bricks orother building units. The blocks may also be preformed veneer blocks towhich a backing of plastic material has been applied, the layer ofplastic material being of sufiicient thickness to provide forpenetration of the webbing modithereinto. When the plastic material hasset, the blocks become a permanent and rigid attachment to the webbingas shown in Fig. 3. The blocks when cast or formed on the webbing arespaced apart and staggered in brick-like relation to form the spaces 3.It is preferred to form a plurality of rows of blocks on the webbing asshown and the blocks of one row are so offset as to cause staggering ofthe blocks at the ends of the unit to provide for an-interlocking fitwith adjacent units and thereby provide a continuous surface when thesections or units are secured in position. The webbing in Fig. 1 isshown as extended at the left and at the top so as to permit blocks of asection laid at the left and above to overlap the backing of the firstsection.

proper relation with the webbing of adjacent units and abut the latter.

With the form of construction illustrated in Fig. 7 only one tile orblock 2a. is formed on the webbing 1a and the webbing is shaped toextend beyond all of the edges of the block as at 3a.

In the form of invention illustrated in Fig. 6, a plurality of blocks 2are cast on a backing l in the same manner as above described but theends of the unit are formed in regular step-like formation, the webbingbeing cut to coincide with the step-like formation at one end of theunit and being caused to project beyond the unit at the other end and atthe top.

With the form of the invention shown in Fig. 8, half blocks or tiles aredeposited or molded simultaneously onto the webbing from opposite sidesto form a construction in which the webbing is midway between theblocks.

The units are further formed with a flat adhesive covering 4, 4a, 4b and4c and this covering is formed of any suitable material either flexibleor rigid, and preferably relatively thin, which will permit temporarysealing of the spaces 3 between the blocks. The covering may be soformed on the units that two adjacent ends will form a flap ofsuificient length to seal the space between the end blocks of adjacentsections when the sections are secured in position on a wall or thelike.

If it is desired to have the binding material so formed that there arevalleys between blocks on the finished wall a covering of the type shownat 4a in Fig. 4 may be utilized, said covering being provided withgrooves which fit in the spaces between the blocks. Similarly if it isdesired that the binding material appear in the form of ridges, acovering of the typeshown at 4b in Fig. 5 may be employed.

In carrying out the improved method of laying the sections, the entireunit as illustrated in Figs. 2, 6 or 7 is pressed with its mesh siderearwardly into a layer of suitable binding material when the latter isin a plastic state, the layer being preferably on the face of thesurface which is to be covered, causing said material to be forcedthrough the openings in the webbing and into the spaces between theblocks until the material contacts with the underside of the covering 4,4a, 4b or 40. This permits a bond to be made between the back and thesides of each block and the web connecting them and between the adjacentsides of blocks of adjacent units. After the binding material has setthe covering sheet 4 is removed and an unstained exterior surfaceresults, the surface, of course, resembling the usual brickconstruction. If a covering sheet apart position on the while the latteris in apertured web into and above the web to the face protecting meanssuch as that shown at 4a has been used, when it is removed the bindingmaterial will be in the form of grooves in the I ing material is in theform 4b the binding material will be in the form of ridges.

It is sometimes desirable in assembly to first take a section formedwith the blocks and to through the webbing as an initial step beforemounting. This will result in the front facing of the mortar joint beingsmooth and in the elimination of holes or unfilled points when thecovering material is removed.

When a large section is being placed in position and pressed into themortar, if the covering material is of a dense nature, some air may betrapped in the spaces between blocks and leave as an only outlet theopen ends of the sections. The above may result in blow holes or pits inthe front face of the mortar joints when the covering is removed. Toavoid this, it is preferred to employ a covering material 4, 4a, 4b or40 which is of such porosity as to permit the passage of air and yetprevent the passage of mortar or binding material therethrough.

The individual units shown in Fig. 7 are laid in an identical manner tothe multiple block units.

With the type of unit shown in Fig. 8 either side may form the exteriorsurface of the wall, the covering sheet, of course, being positioned onthe side selected. With the reversible unit shown in Fig. 8 one side maybe formed of one color and the other side of another color making itpossible for a color selection to be made.

All of the various units shown are so laid as to present a continuousbrick-like appearance. The blocks may, of course, be made in the form ofsquares, diamonds, hexagons or the like to simulate various other typesof building units.

Other changes and modifications may be made without departing from thespirit of the invention and all such changes are contemplated as maycome within the scope of the claims.

What I claim is:

1. The method of forming siding or the like comprising providing a blockof plastic material on an apertured web wherein the web extends be yondedges of the block, applying a layer of binding material to a wall orthe like to be covered, and pressing the mounted blocks into spacedlayer of binding material a plastic state, forcing the binding materialthrough the apertured web into the spaces between blocks above the weband causing a union between blocks and between projecting web portionsin said spaces.

2. The method of forming siding or the like comprising providing a blockof plastic material on an apertured web wherein the web extends,

beyond edges of the block, securing to the face of the block to beexposed a temporary protecting means which also projects beyond theedges of the block, applying a layer of binding material to a wall orthe like to be covered, pressing the mounted blocks into spaced apartposition on the layer of binding material while the latter is in aplastic state and the'protecting means covering the spaces betweenblocks, forcing the binding material through the the spaces betweenblocks with projecting portions of V and causing a union between blocksand between projecting web portions in said spaces.

3. The method of forming siding or the like comprising providing aplurality of blocks of plastic material in spaced apart relation on anapertured web wherein the web extends beyond edges of the blocks,applying a layer of binding material to a wall or the like to becovered, and pressing a plurality of sets of mounted blocks into spacedapart position on the layer of binding material while the latter is inaplastic condition, forcing the binding material through the aperturedweb into the spaces between blocks and sets of blocks and above the weband causing a union at said spaces between the blocks and betweenprojecting web portions.

4. The methodof forming siding or \the like comprising providing aplurality of blocks of plastic material in spaced apart relation on anapertured web wherein the web extends beyond edges of the blocks,securing to the blocks a temporary covering closing the spaces betweenblocks at the sides to be exposed to protect said sides duringapplication, applying a layer of binding material to a wall or the liketo be covered, pressing a plurality of sets of mounted blocks intospaced apart position on the layer of binding material while the latteris in a plastic condition, forcing the binding material through theapertured web into the spaces between blocks and sets of blocks andcausing a union between the blocks and above the web to the temporarycovering and. between projecting web portions in said spaces.

5. The method of forming siding or the like comprising providing a blockof plastic material on an apertured web wherein the web extends beyondedges of the block, securing to the block at the side to be exposed whenlaid a temporary covering sheet projecting beyond edges thereof andformed to create a desired surface effect on the binding materialadjacent the sides of the block when laid, applying a layer of bindingmaterial to a wall or the like to be covered, pressing the mountedblocks int'o spaced apart position on the layer of binding materialwhile the latter is in a plastic state, forcing the binding materialthrough the apertured web into the spaces between blocks to the coveringsheet and causing a union between blocks and between projecting webportions.

6. A building unit web, a block formed of plastic material rigidlymounted on said web, and a covering sheet porous to air temporarilysecured to a face of the block to be exposed and projecting beyond edgesthereof, said projecting covering sheet adapted to prevent exudation ofbinding material to the face of the block when laid.

'7. A building unit comprising a mesh web, a block formed of plasticmaterial rigidly mounted on said web adjacent one of its sides, and acovering sheettemporarily secured to another side of the block andprojecting beyond edges thereof, said covering sheet being pervious toair and substantially impervious to a binding material when securing theunit to a base.

8. A building unit comprising an apertured web, a plurality of blocksformed of plastic material rigidly mounted on said web in spacedrelation to one another, and a covering sheet temporarily securedadjacent the side of the unit to be exposed and projecting beyond edgesthereof to seal the spaces between blocks, and binding material in thespaces between blocks and adjacent the covering sheet, said coveringsheet preventing exudation of binding material before and duringapplication of the unit.

9. A building unit comprising an apertured web,

comprising an apertured.

a block formed of plastic materialrigidly mounted on said web and havingthe web imbedded therein on one side thereof, temporarily secured toanother side of the block and projecting beyond edges thereof, the webalso and a covering sheet projecting beyond edges of the block but alesser amount.

10. A reversible building unit comprising an apertured web, facingblocks formed of plastic material mounted on opposite sides of the webin coincident positions and having the web imbedded into the juncturethereof, the faces of the blocks on opposite sides of the web presentingcontrasting colors.

11. A reversible building unit comprising a mesh web, facing blocksformed of plastic material with a veneer facing mounted on oppositesides of the web in coincident positions and having the web imbeddedinto the juncture'thereof, the faces of the blocks on opposite sides ofthe web presenting contrasting effects.

12. A reversible building unit comprising an apertured web, blocksformed of plastic material mounted on opposite sides of the web incoincident positions and having the web imbedded into the juncturethereof, and a covering sheet temporarily secured to the face of theblock on the side to be exposed when laid and projecting beyond edgesthereof, the faces of the blocks on opposite sides of the unitpresenting contrasting colors.

13. A building unit comprising a plurality of blocks, apertured means inrigid connection with said blocks for holding the same in assembledspaced apart relation to one another, and means for temporarily coveringone side of the unit to prevent binding material entering from anotherside thereof and passing through said apertured web'and into the spacesbetween blocks, from staining the first mentioned side.

14. A building unit comprising an apertured web, a block formed ofplastic material rigidly mounted on said web, and a covering sheettemporarily secured to a face of the blockto be exposed and projectingbeyond edges thereof, the projecting portions of the covering sheetbeing formed to create a desired surface impression on binding materialapplied adjacent the sides of the block.

15. A building unit comprising an apertured web, a block formed ofplastic material rigidly mounted on said web, and a covering sheettemporarily secured to a face of the block to be exposed and projectingbeyond edges thereof, the projecting portions of the covering sheetbeing formed to create surface grooves on binding material appliedadjacent the sides of the block.

16. A building unit comprising an apertured web, a block formed ofplastic material rigidly mounted on said web, and a covering sheettemporarily secured to a face of the block to be exposed and projectingbeyond edges thereof, the projecting portions of the covering sheetbeing formed to create surface ridges on binding material appliedadjacent the sides of the block.

1'7. A building unit comprising an apertured web, a block formed ofsuitable material mounted on said web, and a covering member temporarilysecured to a front portion of the block and projecting beyond edgesthereof, the projecting portions of the covering sheet being formed tocreate a desired surface effect on binding material applied adjacent thesides ofthe blocks.

18. A building unit comprising a plurality of spaced apart blocks,apertured means in 0011-. nection with one side of said blocks formaintainling definite spacing thereof, and covering means porous to airsecured to an opposite portion of and web portions, and removing saidcovering means after the binder has set.

binding material to a wall or thereafter removing the said means alsosealing applying a layer 01' the like to be covporary protecting means,the spaces between blocks,

